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PDS DATA HANDBOOK – 2021 EDITIONReliability Datafor Safety EquipmentSINTEF Digital
SINTEF DigitalMaria Ottermo, Stein Hauge and Solfrid HåbrekkeReliability Data for Safety EquipmentPDS Data Handbook – 2021 Editionwww.sintef.no
Maria Ottermo, Stein Hauge and Solfrid HåbrekkeReliability Data for Safety EquipmentPDS Data Handbook – 2021 EditionKeywords:Safety, Reliability Data, Safety Instrumented Systems (SIS), SIL calculationsISBN 978-82-14-06468-1SINTEF Report no. 2021:00370printed by 07 Media ASContent: 115 g G-printCover: 250 g Galerie Art Silk Copyright SINTEF 2021The material in this publication is covered by the provisions of the NorwegianCopyright Act. Without any special agreement with SINTEF, any copying and makingavailable of the material is only allowed to the extent that this is permitted by law orallowed through an agreement with Kopinor, the Reproduction Rights Organisationfor Norway. Any use contrary to legislation or an agreement may lead to a liability fordamages and confiscation, and may be punished by fines or imprisonment.SINTEF DigitalSoftware Engineering, Safety and SecurityAddress:NO-7465 TrondheimNorwayTelephone: 47 40 00 51 PDSwww.sintefbok.no
SINTEF DigitalSINTEF DigitalAddress:Postboks 4760 TorgardenNO-7465 TrondheimNORWAYSwitchboard: 47 40005100info@sintef.noEnterprise /VAT No:NO 919 303 808 MVAKEYWORDS:Reliability dataFailure ratesSafety systemsSIL calculationsReportReliability Data for Safety EquipmentPDS Data Handbook – 2021 EditionVERSIONDATE2021-05-30FINALAUTHORSMaria Ottermo, Stein Hauge and Solfrid HåbrekkeCLIENT(S)CLIENT’S REF.Multiclient – PDS ForumMathilde CotPROJECT NO.NUMBER OF PAGES:60S051214ABSTRACTThis handbook provides reliability data based on field feedback for components of safetyinstrumented systems, subsea and drilling equipment, and selected non-instrumentedsafety critical equipment. Considerable effort has been made to ensure that the data arecredible, traceable, documented and justified, in line with requirements in the IEC 61508and IEC 61511 standards. Compared to the 2013 edition of the handbook, the mainchanges are: Greatly expanded data basis, including comprehensive and more recentoperational experience. New equipment groups are added. For several sensors and final elements, the failure rates differentiate betweenrelevant attributes such as dimension, measuring principle, process service, etc. Updated values for the common cause factor (𝛽 factor), diagnostic coverage (DC)and random hardware fraction (RHF). Improved data traceability and a more detailed assessment of data uncertainty.In addition, failure rates, equipment boundaries, failure definitions and other relevantinformation have been updated or included.PREPARED BYMaria Ottermo, Stein Hauge and Solfrid HåbrekkeCHECKED BYTor OnshusAPPROVED BYLars Bodsberg, Project DirectorREPORT NO.ISBNCLASSIFICATIONCLASSIFICATION THIS icted3 of 216
Reliability Data for Safety EquipmentPDS Data Handbook, 2021 EditionTable of contentsPREFACE. 81INTRODUCTION . 91.1 Objective and Scope . 91.2 The IEC 61508 and 61511 Standards . 91.3 Data Sources . 101.4 Organisation of the Data Handbook . 121.5 List of abbreviations . 122RELIABILITY CONCEPTS – THE PDS METHOD . 152.1 The PDS Method . 152.2 Notation and Definitions. 152.3 Failure Classification Schemes . 162.3.1 Failure Classification by Mode . 162.3.2 Failure Classification by Cause . 172.4 Reliability Parameters . 182.4.1 The Beta (𝛽) factor and CMooN . 182.4.2 Safe Failure Fraction (SFF) . 192.4.3 Diagnostic coverage (DC) and proof test coverage (PTC) . 192.4.4 Random Hardware Failure fraction (RHF) . 203RELIABILITY DATA SUMMARY . 213.1 Topside Equipment . 213.1.1 Input devices. 213.1.2 Control logic units . 223.1.3 Final elements. 233.2 Subsea and Downhole Well Completion Equipment . 263.3 Drilling Equipment . 283.4 Generic 𝛽 values . 283.5 Determining Diagnostic Coverage (DC). 293.5.1 Instrument DC in general – Relevant data sources . 303.5.2 Equipment specific (instrument) DC values. 303.5.3 Diagnostic success . 333.6 Determining values for Proof Test Coverage (PTC) . 333.6.1 Semi-quantitative approach for determining PTC . 333.6.2 PTC for input elements/sensors . 3460S0512021:003704 of 216
Reliability Data for Safety EquipmentPDS Data Handbook, 2021 Edition3.73.843.6.3 PTC for final elements . 34Random Hardware Failure Fraction (RHF) . 363.7.1 RHF for input elements/sensors . 383.7.2 RHF for control logic units . 383.7.3 RHF for final elements . 39Reliability Data Uncertainties – Upper 70% values and 90% confidence intervals . 393.8.1 Failure Rate Uncertainties . 393.8.2 Upper 70% limits and 90% confidence interval estimates . 40DATA DOSSIERS . 464.1 Explanation of data dossier fields . 464.2 Topside Input Devices . 494.2.1 Position Switch . 494.2.2 Aspirator system including flow switch etc. . 504.2.3 Pressure Transmitter . 514.2.4 Level Transmitter . 534.2.5 Temperature Transmitter . 554.2.6 Flow Transmitter . 574.2.7 Catalytic Point Gas Detector . 594.2.8 IR Point Gas Detector. 614.2.9 Aspirated IR Point Gas Detector System . 644.2.10 Line Gas Detector . 664.2.11 Electrochemical Detector . 694.2.12 Smoke Detector . 724.2.13 Heat Detector . 764.2.14 Flame Detector . 794.2.15 Manual Pushbutton (outdoor) . 824.2.16 CAP switches (indoor) . 864.3 Control Logic Units (topside applications) . 874.3.1 Standard Industrial PLC. 884.3.1.1 Analogue Input . 884.3.1.2 Central Processing Unit (CPU) . 894.3.1.3 Digital Output . 904.3.2 Programmable Safety System. 914.3.2.1 Analogue Input . 914.3.2.2 Central Processing Unit (CPU) . 924.3.2.3 Digital Output . 934.3.3 Hardwired Safety System . 944.3.3.1 Trip Amplifier . 944.3.3.2 Logic . 9560S0512021:003705 of 216
Reliability Data for Safety EquipmentPDS Data Handbook, 2021 Edition4.460S0514.3.3.3 Digital Output . 964.3.4 Other Control Logic Units . 974.3.4.1 Fire Central . 974.3.4.2 Galvanic Barrier . 98Topside Final Elements . 994.4.1 Topside ESV and XV . 994.4.1.1 Topside ESV and XV - Ball Valves . 1034.4.1.2 Topside ESV and XV – Gate Valves . 1054.4.2 Riser ESV . 1074.4.3 Topside XT Valves – PMV and PWV . 1094.4.4 Topside XT Valves – HASCV . 1114.4.5 Topside XT Valves – GLESDV . 1124.4.6 Topside XT Valves – CIESDV . 1134.4.7 Topside HIPPS Valves . 1144.4.8 Blowdown Valves. 1164.4.9 Fast Opening Valves. 1184.4.10 Solenoid/Pilot Valves . 1204.4.11 Process Control Valves . 1214.4.12 Pressure Relief Valve . 1224.4.13 Deluge Valves . 1244.4.14 Fire Water Monitor Valves . 1264.4.15 Fire Water Monitors . 1274.4.16 Water Mist Valves. 1284.4.17 Sprinkler Valves . 1304.4.18 Foam Valves . 1314.4.19 Ballast Water Valves . 1324.4.20 Fire Water Pump System – Diesel Electric . 1334.4.21 Fire Water Pump System – Diesel Hydraulic . 1374.4.22 Fire Water Pump System – Diesel Mechanical . 1404.4.23 Fire & Gas Damper. 1424.4.24 Rupture Disc . 1444.4.25 Circuit Breaker . 1464.4.26 Relay, Contactor . 1474.4.27 Fire Door . 1484.4.28 Watertight Door . 1494.4.29 Emergency Generator. 1504.4.30 Lifeboat Engines. 1514.4.31 UPS & Battery Package . 1524.4.32 Emergency Lights . 1534.4.33 Flashing Beacons. 1542021:003706 of 216
Reliability Data for Safety EquipmentPDS Data Handbook, 2021 Edition4.54.64.74.4.34 Lifeboat Radio . 1554.4.35 PA Loudspeakers. 156Subsea Equipment . 1574.5.1 Subsea Pressure Sensor . 1584.5.2 Subsea Temperature Sensor. 1594.5.3 Combined Subsea Pressure and Temperature Sensor . 1604.5.4 Subsea Flow Sensor . 1614.5.5 Subsea Sand Detector . 1624.5.6 Master Control Station . 1634.5.7 Umbilical Hydraulic/Chemical Line . 1644.5.8 Umbilical Power/Signal Line . 1664.5.9 Subsea Solenoid Control Valves . 1674.5.10 Subsea Electronic Module . 1684.5.11 Subsea Manifold Isolation Valve . 1694.5.12 Subsea XT Valves – PMV, PWV . 1704.5.13 Subsea XT Valves – XOV . 1724.5.14 Subsea XT Valves – AMV . 1744.5.15 Subsea XT Valves – CIV, MIV . 1754.5.16 Subsea Isolation Valves – SSIV . 177Downhole Well Completion Equipment . 1794.6.1 Downhole Safety Valves – DHSV . 1804.6.2 Downhole Safety Valve – TRSCSSV . 1824.6.3 Downhole Safety Valve – WRSCSSV . 1854.6.4 Annulus Subsurface Safety valve – TRSCASSV, type A. 1884.6.5 Annulus Subsurface Safety Valves – TRSCASSV, type B . 1904.6.6 Wire Retrievable Chemical Injection Valves – WRCIV . 1914.6.7 Tubing Retrievable Chemical Injection Valves – TRCIV . 1924.6.8 Gas Lift Valves – GLV. 193Drilling Equipment . 1944.7.1 Annular Preventer . 1964.7.2 Ram Preventer . 1984.7.3 Choke and Kill Valve. 2004.7.4 Choke and Kill Line . 2024.7.5 Hydraulic Connector . 2044.7.6 Multiplex Control System . 2064.7.7 Pilot Control System . 2104.7.8 Acoustic Backup Control System . 213References . 21560S0512021:003707 of 216
Reliability Data for Safety EquipmentPDS Data Handbook, 2021 EditionPREFACESINTEF is proud to present this new 2021 edition of the PDS1 data handbook. As compared to the 2013 editionof the PDS data handbook [1], the historical data basis has been greatly expanded and the detailing andassessment of the data have been significantly improved. The data have been subject to extensive qualityassurance, where equipment experts and operational personnel have gone through and classified some thirtythousand maintenance notifications and work orders manually. As to our knowledge, this represents one of thebroadest and best documented data bases for safety equipment, worldwide.The work has been carried out as part of the research project “Automized process for follow-up of safetyinstrumented systems” (APOS) and has been funded by SINTEF, the Research Council of Norway, the APOSproject members and the PDS forum participants. We would like to thank everyone who has provided us withquality assured reliability data, comments, and valuable input to this PDS data handbook.Trondheim, May 2021PDS Forum Participants as per 2021Petroleum Companies / Operators: AkerBP Altera Infrastructure ConocoPhillips Norge Equinor Gassco Lundin Energy Neptune Energy Norske Shell OKEA Repsol Norge Vår EnergiControl and Safety System Vendors: ABB Emerson Honeywell Kongsberg Maritime Optronics Technology Origo Solutions Siemens Energy1Engineering Companies and Consultants: Aibel Aker Solutions DNV Norge ORS Consulting Proactima Rosenberg WorleyParsons Safetec Nordic TechnipFMC Vysus GroupGovernmental Bodies (Observers): Norwegian Maritime Directorate Petroleum Safety Authority NorwayPDS is a Norwegian acronym for reliability of Safety Instrumented Systems. See also www.sintef.no/pds.60S0512021:003708 of 216
Reliability Data for Safety EquipmentPDS Data Handbook, 2021 Edition1INTRODUCTION1.1Objective and ScopeThe use of realistic failure data is an essential part of any quantitative reliability analysis. It is also one ofthe most challenging parts and raises several questions concerning the suitability of the data, the assumptionsunderlying the data and the uncertainties related to the data.This handbook provides reliability data for safety equipment, including components of safety instrumentedsystems, subsea and drilling equipment and selected non-instrumented safety critical equipment such asvalves, fire-fighting equipment, fire and gas dampers, fire doors, etc. Efforts have been made to documentthe presented data thoroughly, both in terms of applied data sources, underlying assumptions, anduncertainties in terms of confidence limits.Compared to the 2013 version, the main changes and improvements are: Greatly expanded data basis, including comprehensive and more recent operational experience.New equipment groups have been added, and more detailed failure rates, differentiating onattributes such as dimension, measuring principle, medium, etc., are given for selected sensors andfinal elements.Updated common cause factors (β values) based on an extensive field study of some 12.000maintenance notifications, as described in [3].Updated values for diagnostic coverage (DC) and random hardware fraction (RHF) based onoperational experience, vendor certificates and discussions with equipment experts.Improved data traceability and a more detailed assessment of failure rate uncertainty.In addition, failure rates, equipment boundaries including a definition of dangerous (or safety critical)failure, and other relevant information and parameters have been reviewed and updated for all components.This data handbook may also be used in conjunction with the PDS method handbook [2]2, which describesa practical approach for calculating the reliability of safety systems.1.2The IEC 61508 and 61511 StandardsThe IEC 61508 and IEC 61511 standards, [4] and [5], present requirements to SIS for all relevant lifecyclephases, and have become leading standards for SIS specification, design, implementation, and operation.IEC 61508 is a generic standard common to several industries, whereas IEC 61511 has been developedespecially for the process industry. The Norwegian Oil and Gas Association (NOROG) has also developeda guideline to support the use of IEC 61508 / 61511 in the Norwegian Petroleum Industry [6].A fundamental concept in both IEC 61508 and IEC 61511 is the notion of risk reduction; the higher the riskreduction is required, the higher the SIL. It is therefore important to apply realistic failure data in the designcalculations, since too optimistic failure rates may suggest a higher risk reduction than what is obtainable inoperation. In other words, the predicted risk reduction, calculated for a safety function in the design phase,should to the degree possible reflect the actual risk reduction that is experienced in the operational phase,see also [6].This is also emphasized in the second edition of IEC 61511-1 (sub clause 11.9.3) [4] which states that theapplied reliability data shall be credible, traceable, documented and justified and shall be based on fieldfeedback from similar devices used in a similar operating environment. It is therefore recommended [6] touse data based on actual historic field experience when performing reliability calculations.2The PDS method handbook is currently under revision. A new version is planned to be issued early 2022.60S0512021:003709 of 216
Reliability Data for Safety EquipmentPDS Data Handbook, 2021 EditionThe reliability data in this PDS handbook represent collected experience from operation of safety equipment,mainly in the Norwegian oil and gas industry. As such, the PDS data and associated method are in line withthe main principles advocated in the IEC standards, and the data presented in this handbook are on a formatsuitable for performing reliability calculations in line with the IEC standards.1.3Data SourcesThe most important data source for this handbook is extensive operational experience gathered fromNorwegian offshore (and some onshore) oil and gas facilities during the last 10–15 years. Data from 54different facilities and seven different operators, are represented. In fact, the total accumulated experiencesums up to more than 3 billion operational hours for topside equipment and more than 750 millionoperational hours for subsea and well completion equipment. Note that these data have been subject toextensive quality assurance through the fact that equipment experts and operational personnel have gonethrough and classified thousands of maintenance notifications and work orders manually. As to ourknowledge, this represents one of the broadest and best documented data bases for safety equipment,worldwide.Other data sources applied include: OREDA reliability data ha
This handbook provides reliability data based on field feedback for components of safety instrumented systems, subsea and drilling equipment, and selected non-instrumented safety critical equipment. Considerable effort has been made to ensure that the data are credible, traceable, documented and justified, in line with requirements in the IEC 61508 and IEC 61511 standards. Compared to the 2013 .
